Electrical connector

ABSTRACT

A WEDGE-TYPE ELECTRICAL CONNECTOR ADAPTED TO CONNECT A SMALL TAPOFF WIRE TO A LARGE EXISTING WIRE IS DISCLOSED. THE CONNECTOR IS DEFINED BY A GENERALLY C-SHAPED HOUSING MEMBER MADE OF ELECTRICALLY-CONDUCTIVE METAL SUCH AS ALUMINUM, AND WEDGE MEMBERS MADE OF SIMILAR METAL. THE WEDGE MEMBER IS DRIVEN INTO THE C-SHAPED HOUSING MEMBER TO CONFINE THE WIRES. A NEST MEANS IN THE C-SHAPED HOUSING MEMBER RECEIVES THE TAPOFF WIRE.

United States Patent 1 3,588,791 [72] lnventor Mario l olldori 1.349.16 lO/l967 Mixon etal 1"4/94 Penusauken. NJ

Prtman ExammerMarv1n A. (.hamplon [21] P 9 Assistant Examiner-Robert A.Hafer 1221 AttorneysCurtjs. Morris and Safford.MarshallM. [45] Patented Jig? 1 ed Holcombe,William l-lintze. William J Keating, Frederick [73] Asslgnee A corpora W.Raring,J0hnR Hopkms AdrianJ La Rue and Jay Harrisburg, Pa. Seitchik 541 ELECTRlCAL CONNECTOR 6 Claims, 7 Drawing Figs. [52] US. Cl 339/247, 339/273 l l [In-Cl ABSTRACT: A wedge-type electrical connector adapted to 7/06 connect a small tapoff wire to a large existing wire is disclosed. [50] Field of Search 339/240, The connector is defined by a generally GshaPed housing 7,273,274,276; 24/1251 member made of electrically-conductive metal such as alu- 56 R f ed minum, and wedge members made of similar metal. The l 1 e erences wedge member is driven into the C-shaped housing member to UNITED STATES PATENTS confine the wires. A nest means in the C-shaped housing 2,092,372 9/1937 Goeller 24/l26(.3) member receivesthe tapoffwire.

Patented June 28, 1971 3,588,791

INVENTOR MARIO POLIDORI ELECTRICAL CONNECTOR This invention generally relates to electrical connectors for use in connecting tapoff wires to a line wire without severing the line wire.

In the art of applying electrical connectors onto electrical transmission lines, it is frequently necessary to apply such connector intermediate the ends of the through or existing wire. Prior connectors are generally used to connect a tap wire to a through wire so that electrical service may be fed into individual homes and establishments, but these connectors did not prove satisfactory because of the difference in sizes between the tap wire and through wire. The present invention therefore relates to a connector for connecting a relatively small tap wire from a street light, for example, to a relatively large existing wire or. service conductor.

It is an object of this invention to provide a wedge-type connector for securing a small tapoff wire to a large transmission or service wire.

Another object is to provide a wedge-type connection between a relatively small wire and a relatively large wire.

A further object is to provide nest means in a wedge-type connector for receiving a small wire.

An additional object is a method of making an electrical connector element having a nest means formed in a tapered bight thereof.

Other objects and attainments of the present invention will become apparent to those skilled in the art upon a reading of the following detailed description when taken in conjunction with the drawings in which there is shown and described illustrative embodiments of the invention; it is to be understood, however, that these embodiments are not intended to be exhaustive nor limiting of the invention but are given for purposes of illustration in order that others skilled in' the art may fully understand the invention and the principles thereof and the manner of applying it in practical use so that they may modify it in various forms, each as may be best suited to the conditions ofa particular use.

In the drawings:

FIG. I is a perspective view ofa connector according to this invention connecting a pair of conductors;

FIG. 2 is a fragmentary cross-sectional view of the connection ofFIG.1;

FIG. 3 is another fragmentary cross-sectional view of the connection of FIG. 1;

FIG. 4 is an end view ofthe outer shell ofa connector;

FIG. Sis a fragmentary cross-sectional view of FIG. 4;

FIG. 5A is a fragmentary cross-sectional view of an alternate embodiment ofa C-shaped member; and

FIG. 5B is a fragmentary cross-sectional view of another embodiment ofa C-shaped member.

Referring to FIGS. 1-3, a preferred embodiment of the invention includes a two piece assembly comprising a housing member 2 and a wedge member 6. Housing member 2 is preferably substantially C-shaped in cross section. The housing member 2 has a straight back portion 4, and it receives wedge member 6. The C-shaped housing member 2 has a curved portion or bight 7 which tapers from trailing end 8 to leading end It) of housing member 2 so that the area adjacent trailing end 8 has a greater cross-sectional area than the area adjacent leading end 10.

As shown, particularly in FIGS. 2, 3, and 5, curved portion.

or bight 12 of the C-shaped housing member 2 has an inwardly-directed portion 14 in its outer bottom surface. Two ridges I6 and 18 are spaced and separated by a channel 20, which define nest means internally of said housing to confine a small tap wire 28. This nest is tapered in like manner to that of curved portion 7. A forming die having the configuration of ridges 16, I8 and channel 20 is used to form portion 14, and it is moved forcefully into engagement with the bottom of bight 12 while housing member 2 is held in a stationary position to thereby form the nest area. This operation is performed after a blank of material has been formed into the C-shaped configuration forming housing member 2.

The wedge member 6 is I-shaped and has a pair of concave or arcuate surfaces 22 and 24 on opposite ends thereof. The wedge member is tapered from one end to the other in the same manner as the curved portions 7 and 12. Thus, the taper on the inside surfaces of the curved portions 7 and 12 of the C- shaped member correspond with the taper of the arcuate surfaces 22 and 24.

Referring to FIGS. 1 and 2, a conductor 26, which defines a through distribution wire or line, is disposed between the surface 22 and the bight 7 of the C-shaped member 2. A second conductor, which is small tapoff wire 28, is disposed between surface 24 and within channel 20 of the opposite bight of C- shaped member 2. v

'With the conductors in this position, the wedge member 6 is driven longitudinally relative to the C-shaped member until it is coextensive therewith and housed therein, as shown in FIGS. 1 and 2. The wedge may be driven by power-impacting devices which are actuated by explosive charges, hydraulic, pneumatic or other similar means, or it may be driven by mechanical handle-closing devices. The wedge member may be locked into the C-shaped member by having a section of its small protruding leading end peened over a portion of the straight back portion 4 of the C-shaped member at the leading end thereof. 7

Referring to FIGS. l--3, the resulting mechanical and electrical connection is effected by wedgingly compressing conductor 26 into the tapered bight 7 of C-shaped member 2. The tapoff wire 28 is wedged into tapered channel 20 of the nest means in the bight 12 of C-shaped member 2. The outer ends of concave surface 24 mate with the depressed areas between ridges l6, l8 and back portion 4 and the free end of bight 12 so that wire 28 is trapped therein. The nest means provides residual pressure on the tapoff wire as a result of its tapered and inwardly directed construction. In fact, the construction of member 2 and wedge member 6 is such that when wedge member 6 is forcefully driven into housing member 2 and locked therein to connect wire 28 to wire 26, the connection areas between the wires and the arcuate surfaces 22, 24 of wedge member 6 and the areas of engagement between member 2 and member 4 are scraped to remove oxides thereby forming an excellent mechanical and electrical connection. Also, the seating of wedge member 6 within housing member 2 to form the connection between wires 26 and 28 places the effected connection under residual pressure so that the connection will not work loose as a result of vibration or expansion and contraction environments.

The advantage of this construction is that a considerably larger range of wire sizes may be accommodated within housing member 2. Since the arcuate surfaces 22 and 24 of wedge 6 are similar, wedges of different cross-sectional height may be used in one housing member 2. Therefore, one housing member may be used to connect conductors of similar size, or it may be used to connect an extremely small tapoff wire to a substantially large through distribution line.

Referring to FIG. 5A, the nest means may be made by forming spaced slots 30 and 32 partially along the lower bight of C- shaped member 2, and subsequently forming an axial groove 20'. The slotted section including groove or channel 20' may be then pushed upwardly internally into the C-shaped member, as shown. Groove 20 serves to receive the small tapoff wire 28, as described above. The slotted section tending to return to its original shape results in a residual pressure being applied on the tapoffwire after a connection is made.

Referring to FIG. 58, an alternate nest means may be made by forming slots 30 and 32' into the lower bight of C-shaped member 2. In this embodiment, no axial groove is formed. The slotted section is then pushed upwardly into the C-shaped member, as shown. Conductor-receiving surface or channel 21 in this embodiment is defined as a portion of the curved inside surface of C-shaped member 2. Residual pressure is also achieved in a connection made by this connector.

It will, therefore, be appreciated that the aforementioned and other desirable objects have beenachieved; however, it

should be emphasized that the particular embodiments of the invention, which are shown and described herein, are intended as merely illustrative and not as restrictive of the invention.

lclaim:

1. An electrical connector for connecting a'small wire to a large wire, comprising: a housing member having spaced bights extending from aleading edge to a trailing end thereof and being tapered, one of said bights having-a dimension for receiving a section of the large wire, the outer surface of another of said bights being provided with an inwardly directed portion forming raised nest means internally of said housing, said nest means having a dimension less than the dimension of said another of said bights for receiving a section of the small wire, and a wedge member having spaced areas provided with concave surfaces of tapered configurations corresponding to the tapered configurations of said spaced bights for mating engagement within said housing member to effect an electrical connection between the sections of the wires when disposed within said spaced bights.

2. An electrical connector according to claim 1 wherein said housing member has a C-shaped configuration in cross section.

3. An electrical connector according to claim 1 wherein said nest means includes ridges on each side of a channel means.

4. A connector element'according to claim 1 wherein longitudinal slots are formed on each side of said inwardly struck portion.

5. The structure as recited in claim 1, wherein, said inwardly struck portion is formed by two spaced slots in the outer surface of said another bight, and said raised nest means includes a slotted section defined by said spaced slots, said slotted section projecting internally of said housing member.

6. The structure as recited in claim 5, wherein, said slotted section is further provided with a groove. 

